Ecologically Sustainable Structural Panel

ABSTRACT

An ecologically sustainable structural panel. The structural panel comprises of a unique gage frame, expanding foam, and ecologically sustainable exterior sheathing boards. The ecologically sustainable structural panel is fireproof, water proof, mold proof, asbestos free, impact resistant, moisture resistant, and bacteria resistant. The ecologically sustainable structural panel is also capable of withstanding winds of up to 150 miles per hour due to unique operative connections between male junctions, female junctions, L-junctions, anchors, and the utilization of pins instead of screws.

BACKGROUND

The inventor of the present invention has been in the constructionindustry for 15 years and has a background in engineering. During hisperiod of working in the construction industry he identified a problemwith existing structural panels.

One of the major problems with the structural panels presently used isthat they use Expanded Polystyrene (hereinafter referred to as “EPS”)materials during fabrications. EPS materials are used to insulate thepanels. However, EPS materials are toxic and highly flammable. Thepresent invention uses expandable foam from the amino resin family,consisting of phenol, urea, and melamine coupled with an aldehyde toobviate the toxicity normally present in EPS when fabricating structuralpanels.

Another danger of using EPS material based structural panels is thatwhen they catch on fire, the EPS material structural makeup collapses,thereby making any structure constructed using the structural panelsstructurally deficient. The present invention uses an amino resin foammaterial to insulate the structural panels. This amino resin foam has ahigh melting point, is resistance to moisture, and is resistance tobacteria. The amino resin foam increases the structural makeup ofstructural panels using this material.

The inventor first identified the toxic and structural elements thatwere problematic in the structural panel industry in 2003 and workeddiligently to find a solution to the problem. The solution consisted offinding a material that would have a high melting point and that at thesame time would not be toxic upon being ignited.

The inventor's research also lead him to discover that structural panelsheathing boards could be fabricated from two chief ingredients:magnesium oxide, which is a fireproofing material, and gypsum, whichprovides good finishing qualities and cementing characteristics forstructural panels. The sheathing boards were rigid enough to act asstructural paneling and provided the further advantage of beingrecyclable.

The above findings caused the inventor first to create sheathing boardsfrom magnesium oxide and gypsum. He then procured expandable foamcomposed of amino furin resins. He then filled the hollow space betweentwo sheathing boards with the expandable foam and finally used pins toattach the sheathing boards. This produced an ecologically sustainablestructural panel that was fire proof, mold proof, moisture resistant,bacteria resistant, and free of asbestos, and metals. However, thestructural panel still lacked the structural integrity to withstandstrong winds and sudden impacts.

The inventor further realized that the best way to achieve structuralintegrity was to provide a frame for the structural panel. He recalledthat L-junctions were efficacious in providing resistance to verticalforces such as hurricane strength winds. He also knew that male andfemale junctions would reinforce each other and provide the synergy tocreate a strong overall frame. After trial and error, he createdgalvanized steel stud members having a substantially U-shapedcross-section. The stud members slid into each other to create a hollowrectangular stud member. The inventor then connected the stud membersinto a frame by utilizing male junctions, female junctions, L-junctionsand pins. He then anchored the frame to the floor surface with anindustrial grade 5 ⅛×4 inch anchor screw. The inventor next filled inthe hollow space between the rectangular stud member with the expandablefoam. Finally, he sandwiched the frame between two sheathing boards tocreate his ecologically sustainable structural panel.

Structural panels have been used in the construction industry in thepast, yet none with the present characteristics of the presentinvention. See U.S. Pat. Nos.: 4,765,105; 4,578,909; 2008/0115442;2009/0056255; and 3,797,190.

For the foregoing reasons, there is a need for an ecologicallysustainable structural panel that is fireproof, water proof, mold proof,asbestos free, impact resistant, moisture resistant, bacteria resistant,and that can withstand winds of up to 150 miles per hour.

SUMMARY

The present invention is directed to an ecologically sustainablestructural panel that is fireproof, water proof, mold proof, asbestosfree, impact resistant, moisture resistant, and bacteria resistant. Theecologically sustainable structural panel is also capable ofwithstanding winds of up to 150 miles per hour due to unique operativeconnections between male junctions, female junctions, L-junctions,anchors, and the utilization of pins instead of screws.

The present invention is an ecologically sustainable structural panel.The structural integrity of the structural panel comes from its uniquegage frame and expanding foam. The gage frame is composed of galvanizedsteel stud members designed to fit together for maximum structuralreinforcement. The stud members, which have a U-shaped cross-section areconstructed to slide into each other, forming a hollow and substantiallyrectangular stud member. Male junctions, female junctions, L-junctions,pins, and anchors located at the ends of the stud members connect toform secure connections. Electrical pvc pipes are also embedded into thegage frame to increase structural integrity. Since the gage frame ismade of galvanized steel, it is fireproof. A unique expanding foamcomposed of an amino resin fills a cavity located inside the hollow andsubstantially rectangular stud member and provides desirable propertiesfor the structural panel such as recyclability, fire resistance, moldresistance, impact resistant, moisture resistance, and bacteriaresistance. Exterior sheathing boards composed chiefly of gypsum andmagnesium oxide sandwich the gage frame to form the complete structuralpanel. The sheathing boards are also recyclable, fire proof, mold proof,impact resistant, moisture resistant, bacteria resistant, and do notcontain metals, or asbestos. Furthermore, the complete structural panelis prefabricated; prefabrication reduces the time normally spentinstalling structural panels.

An object of the present invention is to provide a structural panel thatis fireproof, water proof, mold proof, asbestos free, impact resistant,moisture resistant, bacteria resistant, and that can withstand winds ofup to 150 miles per hour.

Another object of the present invention is to reduce construction costsby providing a prefabricated structural panel, and using pins instead ofscrews for operative connectivity.

Yet another object of the present invention is to provide a ecologicallysustainable, recyclable structural panel free of organic solvents, oils,and toxins.

DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood with regard to the followingdescription, appended claims, and drawings where:

FIG. 1 is a side view of the present invention;

FIG. 2 is a cross-sectional view of the present invention; and

FIG. 3 is a frontal view of the present invention.

DESCRIPTION

One embodiment of the ecologically sustainable structural panel 200 isseen in FIGS. 1-3. The ecologically sustainable structural panel 200 isused to provide structural paneling that is fireproof, water proof, moldproof, asbestos free, moisture resistant, and bacteria resistant. Theecologically sustainable structural panel 200 is also capable ofwithstanding winds of up to 150 miles per hour due to its unique use ofjunctions and fittings.

The ecologically sustainable structural panel 200 comprises of at leasttwo exterior sheathing boards 10 comprised of a mixture of magnesiumoxide and gypsum, whereby a rigid surface will be provided. Theecologically sustainable structural panel 200 also comprises of a gageframe 20 for providing structural integrity. The gage frame 20 comprisesof a plurality of stud members 30. Each stud member 30 defines at leastone end 35. Each stud member 30 further defines at least one junction 37at the ends 35 of the stud member for structural reinforcement. The studmember 30 ends 35 utilize either a male junction 70 for structuralreinforcement, a female junction 80 for structural reinforcement, or anL-junction 90 for structural reinforcement, whereby the stud members 30connect to each other using the male junctions 70, the female junctions80, and the L-junctions 90 located at their two ends 35, along with aplurality of pins 100. Each stud member 30 further defines asubstantially U-shaped cross-section 40. Each U-shaped cross-section 40defines a small variance in width so that when two opposing stud members30 slide together, they form a hollow and substantially rectangular studmember 50. Each hollow and substantially rectangular stud member 50defines an opening 60 along its longitudinal axis suitable for injectingan amorphous material inside a cavity in the opening 60 of the hollowand substantially rectangular stud member 50. The ecologicallysustainable structural panel 200 further comprises of an expandable foam110 composed of an amino resin, the amino resin comprises of phenol,urea, melamine, and aldehyde. The expandable foam 110 fills the cavityinside the opening 60 of the hollow and substantially rectangular studmember 50. The ecologically sustainable structural panel 200 furthercomprises of a plurality of anchors 120 for securing the gage frame 20to a floor surface 130. After the expandable foam 110 fills the cavityin the hollow and substantially rectangular stud member 50, the exteriorsheathing boards 10 sandwich the gage frame 20 to form a completedecologically sustainable structural panel 200.

In an embodiment of the present invention, the gage frame 20 is made ofgalvanized steel.

In a further embodiment of the present invention, half inch electricalpvc pipes are embedded into the gage frame 20 for structuralreinforcement.

In yet another embodiment of the present invention, the expandable foam110 is water proof, fire proof, mold proof, does not contain metals, orasbestos.

An advantage of the present invention is that the exterior sheathingboards 10 are ecologically sustainable, recyclable, and contain noorganic solvents, oils, or toxins.

Another advantage of the present invention is that it is prefabricatedand ready to install on site, whereby construction costs are reduced byat least 30%.

Another advantage of the present invention is that it comprises of anexpandable foam 110 that is water proof, fire proof, mold proof, anddoes not contain metals, or asbestos.

Yet another advantage of the present invention is that the ends of thestud members 30 are held down by pins 100 rather than screws, wherebyconstruction time and costs are significantly reduced.

Yet another advantage of the present invention is that the gage frame 20is made of galvanized steel rather than wood, whereby the risk of fireis eliminated.

Yet another advantage of the present invention is that it is Floridahurricane tested, STC-Rated 53-54, and ready for all 2007 ICC criteria.

Although the present invention has been described in considerable detailin reference to preferred versions, other versions are possible.Therefore, the spirit and scope of the appended claims should not belimited to the description of the preferred versions contained herein.

What is claimed is:
 1. An ecologically sustainable structural panel,comprising: at least two exterior sheathing boards comprising of amixture of magnesium oxide and gypsum; a gage frame, the gage framedefines a plurality of stud members, each stud member defines two ends,each stud member further defines at least one junction at the end of thestud member for structural reinforcement, each stud member furtherdefines a substantially U-shaped cross-section, the substantiallyU-shaped cross-section has a small variance in width so that two of theopposing stud members slide together to form a hollow and substantiallyrectangular stud member, the hollow and substantially rectangular studmember defines an opening along its longitudinal axis suitable forinjecting an amorphous material, and a plurality of pins for structuralreinforcement, whereby the stud members connect to each other using thejunctions and the pins; an expandable foam comprising an amino resin,the amino resin comprising phenol, urea, melamine, and aldehyde, theexpandable foam is inserted into the hollow and substantiallyrectangular stud member; and a plurality of anchors for securing thegage frame to a floor surface.
 2. The ecologically sustainablestructural panel of claim 1, wherein the junctions are either male,female, or L-shaped.
 3. The ecologically sustainable structural panel ofclaim 2, wherein the gage frame is made of galvanized steel.
 4. Theecologically sustainable structural panel of claim 3, further compriseof at least one electrical pipe that embeds into the gage frame forstructural reinforcement.
 5. The ecologically sustainable structuralpanel of claim 4, wherein each electrical pipe is a half inch pvc pipe.6. The ecologically sustainable structural panel of claim 5, wherein theexpandable foam is ecologically sustainable, recyclable, water proof,fire proof, mold proof, does not contain metals, and does not containasbestos.
 7. The ecologically sustainable structural panel of claim 6,wherein the anchor dimensions are about five and an eighth by about fourinches.